Receptacle with shaped surface

ABSTRACT

The instant invention discloses a receptacle having a shape along the width of its face that is flat in one plane and along its length that has a constant radius. The shape of the face of the receptacle allows for the proper seating of an inserted plug. The shape of a wall plate around the receptacle along a section which runs along its vertical axis defines a surface of positive first differential and zero second differential, comprised of a combination of splines drawn between points of varying distance from a datum plane. The surface has zero second differential when the rate of height increase of individual splines is constant. When ganged with a switch, the front surface of the switch follows the shape of the cover plate.

This application is a divisional of application Ser. No. 10/852,818filed May 25, 2004, which is a continuation in part of application Ser.No. 10/236,406, filed Sep. 6, 2002, which is a continuation in part ofapplication Ser. No. 10/163,488 filed Jun. 6, 2002.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to the field of electricalwiring devices such as, by way of example, electrical switches and/orreceptacles and accessories for said switches and/or receptacles of thetype installed in building walls.

2. Description of the Related Art

When modifying the wiring in an existing building, whether public,commercial or residential by adding a wiring device such as a switch, areceptacle or a combination of switches and receptacles, it is necessaryto cut a hole in a wall of the building, install a box within the hole,attach the box to a vertical stud and install the wiring device(s) intothe box. In new construction, the box is attached to a stud of an openwall and, thereafter, the wall, which may be sheet rock having anopening for access to the box, is placed over the studs. Theconventional wall box has pairs of mounting ears for mounting the wiringdevices to the box. After the wiring devices are connected to thevarious conductors which they will service, each is fastened withthreaded fasteners such as screws to a pair of ears on the box. Theprocess of connecting a wiring device to various conductors and thenattaching the wiring device with the attached wires to the box is donefor each wiring device located within the box. Thereafter, a wall plateis typically positioned around each wiring device in the box.

Typical installations can include one or multiple wiring devicespositioned side by side in a common box. In installations where thereare multiple wiring devices in a common box, the installation of thewall plate can be time consuming. The wiring devices must be alignedwith each other, must be positioned parallel to each other and must bespaced from each other by a distance dictated by the spacing between theopenings or windows in the wall plate. Misalignment and positioningproblems are often caused by wall boxes that are skewed relative to thewall or by walls which may not be flat. It is only after all of thewiring devices are accurately positioned relative to each other that awall plate can be installed around the wiring devices.

A common type of electrical wiring device in use today is the rockertype Decora-branded electrical switch whose activating member pivotsabout a centrally located horizontal axis and is flat in its horizontalplane. The trademark “Decora” is owned by the assignee of the presentinvention. To operate the switch, the rocker paddle (the actuatingmember) is pushed in at the top to supply electricity to a load such asa light, and is pushed in at the bottom to disconnect the source ofelectricity from the load. Thus, with two or more rocker type switchespositioned side by side in a box, the actuating members or paddles ofthe switches can be in opposite positions at any one time. For example,with two or more rocker type switches positioned side-by-side in a box,the top edges of the paddles of the switches will not always be inalignment when they are not all in their “on” or “off” positions. Thein-out positioning of adjacent switches can also occur when all theswitches are in their on or off state if one of the switches is a 3-wayor 4-way switch. The irregular in-out positioning of adjacent switches,particularly with 3-way and 4-way switches, can cause visualinconsistency in the mind of the user as to which switch is on and whichswitch is off when subsequent activation or deactivation of less thanall of the rocker switches is desired by a user. Another type of wiringdevice in use today is a receptacle having a flat face. In normal use,it is not uncommon to gang a receptacle with a switch. A receptacle witha flat face, when ganged with a switch which is not flat in one plane,typically presents a visual discontinuous array of wiring devices whichhomeowners seem to find visually objectionable.

SUMMARY OF THE INVENTION

The present invention discloses a structure which overcomes thedeficiencies with respect to the prior art devices by providing a wiringdevice such as a switch having an actuating paddle which pivots aboutits upper end and is biased with a spring to assume the same at-restposition when either in its on position or its off position. Repeatedpressing and releasing of the lower portion of the face of the rockerpaddle alternately closes and opens a set of contacts within the switchto alternately connect and disconnect a load such as a light from asource of electricity each time the paddle is so pressed. Thus,regardless of whether adjacent switches of a gang of switches are on-offswitches or 3-way switches, they will always be in alignment. An on-offindicator such as a small light may be provided in the paddle toindicate to a user when the contacts of the switch are opened andclosed.

The paddle of the switch has a length-width ratio dimension that isproportioned to provide a finger contact surface of increased area toallow a user to more easily and quickly identify and operate aparticular switch. The vertical axis of the switch has a surface ofpositive first differential, comprised of splines drawn between pointsof varying distance from a datum plane, and has along the horizontalaxis a surface of a positive first differential and negative seconddifferential, comprised of a combination of splines drawn between pointsof varying distance from the datum plane.

A wall plate according to the present invention is located around theswitch and has a single opening for accommodating one or more switches,with no dividing or separating members dividing the single opening, forreceiving one or a gang of two or more wiring devices. The shape of thewall plate around the switch along a section which runs along itsvertical axis defines a surface of positive first differential and zerosecond differential, comprised of a combination of splines drawn betweenpoints of varying distance from a datum plane. The surface has zerosecond differential when the rate of height increase of individualsplines is constant. The paddle of the switch is not located within astationary frame. The wall plate, when composed of non-conductingmaterial, can have a conductive coating on one of its surfaces to helpprovide a conductive path to a ground.

When the wiring device is a receptacle, the face of the receptacleacross its width is flat in one plane and has a substantially constantradius along its length to allow for the proper seating of an insertedplug.

The present invention teaches an alignment plate which is capable ofaccommodating one or more electrical wiring devices. The conventionaldifficulties encountered with respect to mounting and visuallypositioning a plurality of wiring devices such as one or morereceptacles and/or switches in a wall box and then attaching a wallplate are overcome with the use of the alignment plate of the presentinvention. Such difficulties have included attempting to position thewiring devices to be in alignment with each other, attempting toposition the wiring devices to be parallel to each other, attempting toadjust the spacing between the different devices to be relatively equaland uniform, and attempting to fix all of the devices to be flat againstthe wall. The alignment plate of the present invention has a singlecentrally located opening sized to receive one or more wiring devicesand a set of alignment pins for each wiring device. Each set ofalignment pins on the alignment plate is located along a vertical axiswhich defines the longitudinal centerline for a wiring device, and eachwiring device is equipped at or proximate the ends of its associatedground/mounting strap a multi-function clip for frictionally receivingand holding captive an alignment pin on the alignment plate. Thealignment pins accurately position, align and locate all of the wiringdevices relative to each other and, together with the multi-functionclips, establishes a conductive path to ground. Thereafter the alignmentplate and wiring devices attached to the alignment pins on the alignmentplate can be attached to a box with mounting screws. The alignment pinsaccurately position, align and locate the wiring devices and thealignment plate positions all of the wiring devices to a flat plane.

In one embodiment of the switch according to the present invention, anarticulated cam driver coupled to the rocker paddle of the switch causesa cam to rotate first in a clockwise direction and then in a counterclockwise direction each time the rocker paddle is depressed. Alternaterotation of the cam drives a slider member back and forth along a linearaxis to open and close a set of contacts. A leaf spring of predeterminedshape cooperates with a cam follower on the slider member to assist inthe movement of the slider and to determine its rest positions. Aspring, acting through the rigid member, urges the rocker paddle toalways be in its out position when the switch is in its on position andits off at-rest position. An indicator such as an LED located in thepaddle indicates the state of conduction of the switch.

In another embodiment of the switch according to the present invention,the cam driver coupled to the rocker paddle of the switch comprises aninitially flat ribbon of flexible material such as spring steel formedwith a blunt end having a generous radius which drives the cam. A springurges the rocker paddle to always be in its out position when the switchis in its on and off at-rest position.

In still another embodiment of the switch according to the presentinvention, the cam driver coupled to the rocker paddle of the switch isa closely wound spring of, for example, piano wire coupled to a conicalshaped tip which can be of plastic, metal or the like which drives thecam. A spring urges the rocker paddle to always be in its out positionwhen the switch is in its on and off at-rest position.

The foregoing has outlined, rather broadly, a preferred blendingfeature, for example, of the present invention so that those skilled inthe art may better understand the detailed description of the inventionthat follows. Additional features of the invention will be describedhereinafter that form the subject of the claims of the invention. Thoseskilled in the art should appreciate that they can readily use thedisclosed conception and specific embodiment as a basis for designing ormodifying other structures for carrying out the same purposes of thepresent invention and that such other structures do not depart from thespirit and scope of the invention in its broadest form.

BRIEF DESCRIPTION OF THE DRAWINGS

Other aspects, features, and advantages of the present invention willbecome more fully apparent from the following detailed description, theappended claim, and the accompanying drawings in which similar elementsare given similar reference numerals.

FIG. 1 is a front perspective view of a prior art switch and wall plate;

FIG. 2 is a perspective exploded view of a prior art switch, attachmentplate and wall plate, and a box for receiving said prior art device;

FIG. 3 is a front perspective view of a switch and wall plate inaccordance with the principles of the invention;

FIG. 4 is a front perspective view of the switch shown in FIG. 3 showingthe ground/mounting strap and multi-function clips;

FIG. 5 is an exploded view of alignment plate, a switch fitted withmulti-function clips on its ground/mounting strap, and a wall plate, allaccording to the present invention;

FIG. 6 is a front view of a receptacle and wall plate;

FIG. 7 is a front perspective view of the receptacle of FIG. 6 showingan exploded view of the ground/mounting strap and multi-function clips;

FIG. 8 is an exploded view of alignment plate, receptacle and wallplate;

FIG. 9 is a front perspective view of alignment plate for a singlewiring device;

FIG. 10 is a perspective view of ground/mounting strap for a wiringdevice;

FIG. 11 is a bottom perspective view showing ground/mounting strapattached to a switch;

FIG. 12 is a plan view of a multi-function clip according to the presentinvention, which is normally attached to the bottom end of theground/mounting strap;

FIG. 12A is a side view of the multi-function clip of FIG. 12;

FIG. 13 is a plan view of multi-function clip normally attached to thetop end of the ground/mounting strap;

FIG. 13A is a sectional view of the multi-function clip of FIG. 13 takenalong line 13A-13A;

FIG. 14 is an exploded perspective view of structure of the switch ofFIG. 4;

FIG. 15 is a perspective view of the base assembly of the switch of FIG.14;

FIG. 16 is an exploded perspective view of the structure of the baseassembly of FIG. 15;

FIG. 17 is another exploded perspective view of the switch according tothe present invention;

FIG. 18 is still another exploded perspective view of the switchaccording to the present invention;

FIG. 19 is a partial sectional exploded view of the cam driver of theswitch of FIG. 18;

FIG. 20 is a perspective exploded view of the switch of FIG. 18including a printed circuit board;

FIG. 21A is a plan view of the printed circuit board of FIG. 20;

FIG. 21B is a bottom perspective view of the printed circuit board ofFIG. 21A;

FIG. 22 is a perspective exploded view showing a light pipe in thepaddle of the switch;

FIG. 23 is a perspective view of the light pipe;

FIG. 24 is a sectional view taken along the line 24-24 of the switch ofFIG. 3;

FIGS. 25A-25C are sectional views along the lines 25A-25A, 25B-25B,25C-25C of the paddle of FIG. 14;

FIG. 26 is a perspective exploded view of the switch having another camdriver;

FIG. 27 is a sectional view along the line 24-24 of FIG. 3 where the camdriver is that shown in FIG. 26;

FIG. 28 is a perspective exploded view of the switch having stillanother cam driver;

FIG. 29 is a sectional view along the line 24-24 of FIG. 3 where the camdriver is that shown in FIG. 28;

FIG. 30 is a front perspective view of a wall plate according to thepresent invention for accommodating a single wiring device;

FIGS. 31A-31C are sectional views taken along the lines 31A-31A, 31B-31Band 31C-31C of the wall plate of FIG. 30;

FIG. 32 is a sectional view of the bottom edge of the wall plate of FIG.30 along the line 32A-32A;

FIG. 33 is a sectional view of the top edge of the wall plate of FIG. 30along the line 33A-33A;

FIGS. 34, 34A are views of the top edge of the wall plate of FIG. 30;

FIG. 35 is a fragmentary, enlarged perspective of the pawl of themulti-function clip engaging the tooth shaped rack of the wall plate;

FIG. 36 is a fragmentary, enlarged sectional side view of the wall plateand tab of the alignment plate to indicate how the two components can beseparated following latching;

FIG. 37 is an exploded perspective view of a box, alignment plate andwall plate capable of accommodating two wiring devices, according to thepresent invention;

FIG. 38 is an exploded view of alignment plate and wall plate capable ofaccommodating three wiring devices;

FIG. 39 is an exploded view of alignment plate and wall plate capable ofaccommodating four wiring devices;

FIG. 40 is an exploded view of alignment plate and wall plate capable ofaccommodating five wiring devices; and

FIG. 41 is an exploded view of alignment plate and wall plate capable ofaccommodating six wiring devices.

DESCRIPTION OF A PREFERRED EMBODIMENT

Referring to FIG. 1, there is illustrated a front perspective view of aprior art “Decora” type electrical wall-type switch 18 and wall plate 16forming assembly 10. Referring to FIG. 2, there is shown a perspectiveexploded view of a box 13 and the prior art switch 18, wall plate 16 andattachment plate 30. A suitable aperture is cut into a wall (where thereis an existing wall and this installation is not a new construction) toprovide access to the box 13 mounted to a stud 15, or to permitinstallation of a suitable box directly to the material of the wall(such as plasterboard). The box 13 is chosen to be large enough toaccept as many wiring devices as are to be mounted therein. The box 13is made of metal or plastic, depending upon local electrical Coderequirements, and has one or more openings in its sides or back topermit the introduction of electrical wiring or cables into the interiorof the box 13. Box 13 has mounting means 19 to permit the box to beanchored to an adjacent stud 15. The box is formed with a pair ofmounting ears 21 for each wiring device that is to be mounted within thebox. Each mounting ear contains a threaded aperture 23 for receiving amounting screw of an associated wiring device such as, for example,switch 18 or a receptacle (not shown in FIG. 2). In the normal order ofassembly, electrical cables are passed through knock out openings 17,for example, to the interior of the box. The ends of the electricalcables are stripped of insulation and attached to terminals (contacts)on the side or rear of the body 20 of the switch 18 or a receptacle.After the electrical cables are attached to terminals on the side orrear of the body 20 of the switch (or receptacle), the switch is pushedinto the box and is held in position within the box by screws (notshown) that pass through clearance openings such as elongated mountingslots 25 formed in the mounting strap of the switch and thereafter intothreaded engagement with threaded apertures 23 of ears 21, therebysecuring switch 18 within and to the box 13. Thereafter, a conventionalattachment plate 30 is positioned around the front of the switch andsecured to the switch with mounting screws 26 which pass throughclearance openings 32 in the attachment plate and are threaded intoopenings 24 formed in the ground/mounting strap of the wiring device.Attachment plate 30 contains a main aperture 34 of a shape complimentarywith the profile of the front of the switch 18, which extends throughit. Main aperture 34 is rectangular to accept the front of the switch 18or a receptacle. The head of the screw which passes through elongatedmounting slot 25 of switch 18 and engages threaded aperture 23 ofmounting ears 21 is larger than the inner dimension of slot 25 and,therefore, holds switch 18 or a receptacle captive to the box 13 and toa wall surface (not shown). In a similar manner, the head of the screwwhich passes through clearance opening 32 of the attachment plate 30 andengages threaded opening 24 of the ground/mounting strap of the switchis larger than the diameter of clearance opening 32 and, therefore,holds attachment plate 30 captive to switch 18.

At each of the ends 36, 38 respectively, of attachment plate 30 are twolatching pawls 40, 42 which are formed as extensions of attachment plate30 but which are relatively thinner in cross-section. A narrowprojection 48 located between the latching pawls 40 and bent at about a45 degree angle with respect to the horizontal edge of end 36 of wallplate 30 is used to help release an attached wall plate.

Wall plate 16 is proportioned to fit over attachment plate 30 and box 13into which the single wiring device, such as switch 18, or a receptacle,is placed and to which it is fastened.

To attach wall plate 16 to attachment plate 30, latching pawls 40, 42which are a part of attachment plate 30 are made to engage saw-toothshaped racks 81 on the inner surfaces of end walls 70 and 72 of wallplate 16 as the wall plate is pushed on.

FIG. 3 is a front perspective view of a wiring device such as switch 110and wall plate 138 in accordance with the principles of the presentinvention; FIG. 4 is a front perspective view of the switch 110 of FIG.3 showing the ground/mounting strap 123 and multi-function clips 130,151; and FIG. 5 is an exploded view of FIG. 3 showing alignment plate114, switch 110 with multi-function clips 130, 151 secured onground/mounting strap 123 and wall plate 138. Referring to FIGS. 4 and5, the switch 110 has an actuating rocker paddle 111 which pivots aboutan axis at its upper end and is biased by an internally located springmember to assume the same at-rest position when in both its “on” and“off” position. Repeated pressing and releasing on the face of therocker paddle 111 of the switch alternately closes and opens a set ofcontacts within the switch body to alternately connect and disconnect aload such as a light to a source of electricity each time the paddle ispressed and released. Thus, regardless of whether ganged switches areon-off switches, 3-way switches or 4-way switches, the top and bottomedges of each switch will always be aligned with the top and bottomedges of all the other switches that are ganged together. An on-offindicator such as a light 112 may be provided in the rocker paddle 111to indicate to a user when the switch 110 is in its on position or offposition. For example, when the light 112 is on, the switch will be inits off position, and when the light is off, the switch will be in itson position. Light 112 also serves the purpose of permitting the user tolocate the switch 110 in the dark. The rocker paddle 111 of the switch110 is not located within a frame and aesthetically complements the wallplate 138. The rocker paddle 111 of the switch 110 has a length-widthratio dimension and surface configuration which provides a robust fingercontact surface of increased size which is easier to identify and use.

The switch 110 is attached to a ground/mounting strap 123 having ends122 which provide increased surface area for contact with the surface ofa wall and provides support for multi-function clips 130, 151 attachedto the ends 122 by fastener means such as screws, rivets, spot welds,pressure bonding, TOX process or the like.

Referring to FIG. 10, there is shown a perspective view of theground/mounting strap 123 for a wiring device such as switch 110.Ground/mounting strap 123 has a base support member 150 located betweentwo intermediate support members 152 bent at right angles with respectto the base support member 150 and each of which terminates in anoutward projecting end 122 of the ground/mounting strap. The twointermediate support members 152 and the base support member 150 cradleand are securely attached to the wiring device, such as switch 110, withrivets, screws or the like 155 (see FIG. 11 which is a bottomperspective view showing ground/mounting strap attached to a switch)which pass through openings 154 in the base support member 150. A groundterminal 163 which projects out from the ground/mounting strap 123 andhaving a threaded opening for receiving a screw 127 (see FIG. 5) isprovided for connection to a ground wire. Each end 122 of the strap 123is substantially rectangular in shape and has two openings 126 and 128.Opening 126 can be circular, oval, square or rectangular and is aclearance opening for mounting screws 108 (FIG. 8) which are normallyprovided by the manufacturer of the wiring device for attaching thewiring device to a box. The distance between centers of openings 126 inends 122 of the ground/mounting strap is equal to the distance betweenthe centers of threaded apertures 23 in mounting ears 21 of box 13 (seeFIG. 2) to allow mounting screws 108 to engage and be held captive bythreaded apertures 23. Opening 128 in each end 122 of theground/mounting strap is a clearance opening for an alignment pin whichis a part of and is located on an alignment plate. Additional openingscan be provided in the ends 122 for attaching and/or aligning amulti-function clips 130, 151 to the ends of the ground/mounting strap.The ends 122 are substantially flat rectangular members which provide anincreased area for increased contact with a wall surface. See FIG. 2which shows the relatively small ends of the prior art ground/mountingstrap where, if the scored washers 31 are removed from the strap, theonly surface left for contact with a wall surface is the material aroundthe threaded opening 24 in the ground/mounting strap.

Returning to FIG. 10, the ends 122 of ground/mounting strap 123 has awidth “X” of about 1.563 inches and a depth “Y” of about 0.802 inches.These dimensions are not critical. However, the distance between theedges 129 of the ends 122 of the ground/mounting strap 123 arepreferably not greater than about 4.6 inches to allow a wall plate tofit over and cover the ground/mounting strap. The ground/mounting strap123 can be of conducting material such as steel, etc., and is secured tothe switch with screws, rivets or any convenient fastening means. Screwterminals 137 located on either side of the body of the switch (see FIG.11) are provided to receive phase and neutral wire conductors.

Multi-function clips 130, 151 according to the present invention areattached to the ends 122 of the ground/mounting strap. Themulti-function clips can be composed of phosphor bronze, spring brass,spring steel or the like. Referring to FIG. 12, there is shown a planview of multi-function clip 130 normally attached to the bottom end ofthe ground/mounting strap, and FIG. 12A is a side view of themulti-function clip 130 of FIG. 12. Multi-function clip 130 is attachedto the bottom end 122 of ground/mounting strap 123 and has openings 132and 134. When multi-function clip 130 is attached to the end 122 ofground/mounting strap, opening 132 is aligned with opening 126 of theground/mounting strap, and opening 134 is aligned with opening 128 inthe strap end 122. Opening 132 is a clearance opening for a threadedfastener such as screw 108 (see FIGS. 5 and 8) used to couple the wiringdevice to a box. Opening 132 can be round, square, oval or rectangularto allow the threaded fastener to be moved in all directions to allowthe threaded fastener 108 to be aligned with the threaded aperture inthe box when attaching the wiring device to the box.

Looking at FIG. 12, opening 134 in multi-function clips 130 and 151 isgenerally circular but for three inwardly projecting members 133 whichare formed upwardly at an angle of between 10 degrees and 30 degrees. Anangle of 20 degrees was found to be preferred. The inner ends of thethree inwardly projecting members 133 form an opening slightly smallerthan the outer diameter of an alignment pin 118 on an alignment plate121 (see FIG. 9) and flex or bend upwardly as the alignment pin entersthe opening 134 from the rear. The ends of the projecting members 133frictionally engage and hold captive the alignment pin 118 to preventundesired disengagement of the wiring device from the alignment plate.It is to be noted that the projecting members 133, by physicallycontacting and holding captive the alignment pins 118 on the alignmentplate 121 (see FIG. 9), provide the desired alignment. Located at theend 147 of multi-function clip 130 are two latching pawls 140 eachslightly more than one-half of an inch in length. The end 147 of eachlatching pawl 140 is bent downward at an angle of between 20 degrees and60 degrees and is used to engage tooth shaped racks 80 on the insidesurface of the ends of a wall plate to hold the wall plate captive (seeFIG. 35). The ends 147 of the latching pawls 140 capture and securelyhold the wall plate when the downward bend of the latching pawl 140relative to the ground/mounting strap is between 20 degrees and 60degrees, and where a bend of about 40 degrees was found to be preferable(see FIG. 35). The multi-function clips 130 and 151 are just that clipswhich perform a combination of a plurality of functions not found in theprior art, including accurately aligning one or more wiring devices whenthe multi-function clip of the wiring device engages the alignment pinson the alignment plate; and, holding a wall plate to the wiring deviceand against a wall, even when a wall is not perfectly flat.

The openings 143 in the multi-function clip can be provided forattaching the clip to the end of the ground/mounting strap with, forexample, rivets, screws, the TOX process etc. Openings 145 can beprovided for alignment purposes when attaching the clip to the end 122of the ground/mounting strap 123. The distance between the side edges154 of the multi-function clip should preferably not exceed 1.533 inchesto allow the clip to be attached to the end of the ground/mounting strapwithout extending over the side edges of the strap 123. The clip shownin FIGS. 12 and 12A is the clip that is attached to the bottom end ofthe ground/mounting strap and is slightly different from themulti-function clip that is attached to the top end of theground/mounting strap.

Referring to FIG. 13, there is shown a plan view of the multi-functionclip 151 normally attached to the top end of the ground/mounting strapand FIG. 13A is a sectional side view of the multi-function clip alongline 13A-13A of FIG. 13. The clip 151 shown in FIGS. 13 and 13A issimilar to the clip 130 shown in FIGS. 12 and 12A except that end 157 ofclip 151 is bent upward and opening 153 for the threaded fastener 108(see FIG. 5) has a fastener engaging tab 155 which extends into opening153, and is bent at a slight downward angle toward the back of theswitch. Engaging tab 155 is provided to engage and hold captive thethreaded body of threaded fastener 108 and, in addition, helps toprovide a good electrical connection between the multi-function clip,the ground/mounting strap, the alignment plate and the box as thethreaded fastener is tightened. As with multi-function clip 130,openings 153 in multi-function clip 151 and opening 126 in theground/mounting strap are aligned with each other during assembly topermit the threaded fastener 108 to be aligned with the threadedaperture in the box as the switch is being attached to the box. Thedistance between the side edges 148 of the multi-function clip shouldpreferably not exceed 1.533 inches to allow the multi-function clip tobe attached to the end 122 of the ground/mounting strap and not extendover the side edges of the ends 122 of the ground/mounting strap 123.

Referring to FIG. 6, there is shown a front view of a receptacle 520with its face located within wall plate 138; FIG. 7 is a frontperspective partial exploded view of the receptacle 520 of FIG. 6showing the ends 122 of ground/mounting strap 123 and multi-functionclips 130, 151; and FIG. 8 is a perspective exploded view of FIG. 6showing alignment plate 114, receptacle 520 and wall plate 138.Referring to FIGS. 7 and 8, the receptacle 520 is intended for 15 Amp.125 V to 20 Amp. 125 V where, according to NEMA specification 5-15R,each individual receptacle has two slot openings 524 and 526 forreceiving the flat blades of a suitable plug and a semi-circular groundblade opening 528. Opening 526 is larger than the opening 524 to allow atwo blade plug to be inserted in only one way to maintain correctelectrical polarization. The contact in the larger slot is connected tothe neutral conductor and, by maintaining the correct polarization, theexternal metal parts of appliances such as toasters, TV's etc. can begrounded through the neutral conductor. The semi-circular ground bladeis normally connected to a ground and prevents a plug from making areverse polarity connection with the receptacle and connects it to theground conductor which provides a ground path for the plug-connectedequipment.

Receptacle 520 is attached during assembly to a ground/mounting strap123 as shown in FIG. 10 having ends 122 which provide increased surfacearea for contact with the surface of a wall and provides support formulti-function clips 130, 151 (more fully shown in FIGS. 12, 12A, 13 and13A) attached to the ends 122 of ground/mounting strap 123 by fasteningmean such as screws, rivets, spot welds, pressure bonding, TOX processor the like.

Referring to FIG. 10, as stated above, there is shown a perspective viewof the ground/mounting strap 123 for a wiring device such as areceptacle 520, and (see FIGS. 12, 12A, 13 and 13A) multi-function clipsattached to the ends of the ground/mounting strap. Ground/mounting strap123 and the multi-function clips 130, 151 for a receptacle are similarto the ground/mounting strap and multi-function clips shown anddescribed above for a switch and, therefore, in the interest of brevity,the detailed description of the ground/mounting strap shown in FIG. 10and of the multi-function clips shown in FIGS. 12, 12A, 13 and 13A foruse with a receptacle will not again be here repeated. Themulti-function clips can be composed of phosphor bronze, spring brass,spring steel or the like.

Referring to FIG. 9, there is shown a front perspective view ofalignment plate 114 for a single wiring device such as a switch or areceptacle. Alignment plate 114, which can be composed of any suitablematerial such as brass, aluminum, cold rolled steel, plastic, a plasticcoated with a conducting material, etc., has a centrally located opening116 sized to accept the body of a wiring device. Centrally located atopposite top and bottom ends of opening 116 and either opening into orseparated from opening 116 are two clearance openings 117 for threadedfasteners 108 used to secure the wiring device (a switch or areceptacle) and the alignment plate 114 to box 13 and wall surface. Whenthe wiring device is attached to the box, the alignment plate 114 issandwiched between the ground/mounting strap of the wiring device andthe box. Located between the outer edge of each clearance opening 117and the edge 121 of alignment plate 114 is an alignment pin 118.Clearance openings 117 in alignment plate 114 can have an open end asshown in FIG. 9 or an opening fully encircled by material. When thealignment plate is attached to the ground/mounting strap, openings 128at the ends 122 of the ground/mounting strap are clearance openings foralignment pins 118 and are aligned with openings 134 in multi-functionclips 130,151. Thus, the alignment pins 118 are positioned to enteropenings 134 in multi-function clips 130, 151 attached to the lower andupper ends 122 of the ground/mounting strap 123 of the wiring device asthe wiring device, either a switch or a receptacle, is being attached toan alignment plate. Alignment plate 114 can have two ribs 119 and adownwardly extending tab 120. Tab 120 extends from the bottom edge ofthe alignment plate and is used to facilitate removal of a wall platefrom around the face of a wiring device. The two ribs 119 are present toprovide an alignment plate that resists flexing and is an optionalfeature which is not required as shown for the alignment plate 114 ofFIG. 8. The alignment plate 114, when attached to a wiring device,substantially covers the box in which the wiring device is installed.The alignment plate 114 shown in FIGS. 8 and 9 is for a single wiringdevice.

The alignment plate 114 helps to overcome difficulties encountered withrespect to mounting and positioning wiring devices such as one or moreswitches, a switch and/or a receptacle, or one or more receptacles to abox prior to placing a wall plate around the wiring devices. Prior tomounting a wall plate, various difficulties can be encountered such asaligning the wiring devices with each other, positioning the wiringdevices to be parallel to each other, adjusting the spacing between thewiring devices to be equal and uniform and fixing all of the wiringdevices to be flat against the wall. These difficulties are overcomewith alignment plate 114 which has a single opening 116 and a pair ofalignment pins 118 in combination with the multi-function clips on thewiring devices of each wiring device that is to be mounted to thealignment plate in side by side relationship. The opening 116 in thealignment plate is sized to receive one or a gang of wiring devicespositioned side by side in a box and the alignment plate has a pair ofalignment pins 118 for each wiring device which engage themulti-function clips on each wiring device to hold and accuratelyposition each wiring device relative to each other and along a flatplane. Each set of alignment pins on the alignment plate is located on avertical axis which defines the center for a wiring device and eachwiring device has a multi-function clip at each end of theground/mounting strap for frictionally receiving and holding captive thealignment pins on the alignment plate. When being assembled, the wiringdevices, normally after being connected to the electrical wires, mayfirst be attached to the alignment plate and the alignment plate, whichnow holds captive the wiring devices, is attached to a wall box and wallsurface by means of threaded fasteners. Thereafter, a wall plate ispositioned around the wiring devices without requiring any furtheradjustments on the part of a user by simply pressing the wall plate intoward the wall to allow the latching pawls 140 at the end 147 of themulti-function clips to engage tooth shaped racks 80 on the inside endsof the wall plate.

The multi-function clips, in addition to clamping the wall plate to theground/mounting strap, helps to overcome various difficultiesencountered with respect to mounting and positioning one or moreelectrical wiring devices to a box to allow a wall plate to be quicklyand easily positioned around one or more wiring devices and to also beflat against the wall. Each wiring device according to the presentinvention has at each end of the ground/mounting strap a multi-functionclip that has locating openings 134 for receiving and engaging alignmentpins 118 on the alignment plate 114. The pins on the alignment plate,when engaged by the openings 134 in the multi-function clips, accuratelypositions each wiring device vertically and horizontally on thealignment plate, and the alignment plate itself positions the wiringdevice along a flat plane to allow a wall plate to be positioned arounda single wiring device or a gang of two or more wiring devices withoutany further adjustments being required. Each pair of alignment pins onthe alignment plate is located on a substantially vertical axis whichaccurately defines the center of a wiring device, although it is withinthe scope of the present invention to provide other alignments, as well.The opening 134 in combination with the projecting members 133 in eachmulti-function clip receives and holds captive an alignment pin 118. Themulti-function clips, in cooperation with the alignment pins, accuratelypositions and aligns all wiring devices, either singly or a gangrelative to each other, and to the alignment plate. As noted previously,the opening 116 in the alignment plate can be made to receive one ormore wiring devices. After the wiring device(s) are attached to thealignment plate, the wiring device(s), together with the alignment plateare attached to a wall box and wall surface by means of threadedfasteners such as screws which pass through openings 132 and 153 ofmulti-function clips 130 and 151, openings 126 in the ground/mountingstrap and openings 117 in alignment plate 114. The alignment plate 114provides a substantially flat rigid support for the wiring devices, andthe alignment pins 118, in combination with the multi-function clipsinsures that all the wiring devices are accurately positioned relativeto each other when two or more are ganged together to allow a wall plateto be placed around the wiring devices without requiring any furtheradjustment.

When assembling wiring devices to a wall mounted box, the electricalcables that have been fed through openings to the confines of the boxare stripped of insulation and attached to terminals on the side or backof the wiring device, such as a switch and/or receptacle that is to bemounted in the box. After the wires are attached to the wiring device,the alignment plate may be positioned behind the wiring device bythreading the wiring device through the opening in the alignment plate.The alignment plate may have adhesive strips or the like to facilitatetemporary positioning to the wall surface. The back face of the ends ofthe ground/mounting strap is now moved toward the front face of thealignment plate. As the wiring device moves toward the alignment plate,the alignment pins 118 on the alignment plate enter openings 128 in theground/mounting strap and openings 134 in the multi-function clips 130,151. As the alignment pins enter the openings 134, they force theupwardly bent projections 133 to resiliently move upward and spreadslightly apart to allow the alignment pins to fully enter openings 134.The ends of the upwardly bent projections 133 engage and hold captivealignment pins 118 and resist backward movement and withdrawal of thepins from the openings 134. The body of the switch or receptacle whichis now attached to the alignment plate and connected to the electricalwires, is pushed into the box. As the wiring device is pushed into thebox, threaded fasteners 108 located in openings 132 and 153 in themulti-function clip 130 and opening 153 of multi-function clip 151 andclearance openings 117 in alignment plate 114 are aligned with and arethreaded into threaded apertures 23 in mounting cars of box 13 to holdboth the alignment plate and wiring device(s) to the box and wallsurface. The head of the threaded fasteners which pass through opening126 in the ends of the ground/mounting strap of the wiring device andopenings 132, 153 in the multi-function clips are larger than eitheropening and, therefore, holds the wiring device and alignment plate 114firmly to the box and wall.

The wall plate is now placed over the installed wiring devices. It is tobe noted (see FIGS. 3, 4 and 5) when the wiring device is a switch, ashere disclosed, the rocker paddle 111 of switch 110 is frameless, it isnot located within a frame. Thus, the switch must be accuratelypositioned within the wall plate to insure that the paddle is free tomove without touching either the wall plate or a side surface of anadjacently positioned wiring device.

Each multi-function clip 130, 151 contains two side-by-side latchingpawls 140. See FIGS. 12 and 13. Each latching pawl 140 is bent downwardtoward the back of the wiring device at an angle of about 40 degreesmore or less. After the wiring device is attached to the alignmentplate, the two latching pawls 140 at the ends 147 of the multi-functionclip 130 attached to the bottom end of the ground/mounting strapstraddle downwardly extending tab 120 on the alignment plate. Tab 120(see FIG. 36) which is a part of alignment plate 114 functions as a toolpivot point to allow a wall plate 138 to be easily removed from around aswitch or receptacle. A slot 74, FIG. 5, in the lower edge of the wallplate 138 provides access for the insertion of a small flat tool such asa screw driver to facilitate removal of the wall plate from the wiringdevice.

Wall plate 138 is proportioned to fit over alignment plate 114, the ends122 of the ground/mounting strap 123 and the box within which the wiringdevice is located. The wall plate 138 is located around the wiringdevice and locked in position by pushing the wall plate toward thewiring device until the ends of the latching pawls on the multi-functionclips 130, 151 engage the tooth shaped racks 80 on the inside wall ofthe top and bottom edges of the wall plate.

Referring to FIGS. 14-24, there is shown views of the switch showngenerally in FIGS. 3-5 where FIG. 14 (which illustrates one of severalconstruction embodiments of the present invention, shows a flexibleactuator, as opposed to an alternative embodiment where aplunger/joystick mechanism may be used) is an exploded perspective viewof the switch; FIG. 15 is a perspective view of the base assembly of theswitch of FIG. 14; FIG. 16 is an exploded perspective view of the baseassembly of FIG. 15; FIG. 17 is another exploded perspective view of theswitch; FIG. 18 is still another exploded perspective view of theswitch; FIG. 19 is a partial sectional exploded view of the cam driverof the switch; FIG. 20 is a perspective exploded view of the switchincluding a printed circuit board; FIG. 21A is a plan view of theprinted circuit board; FIG. 21B is a bottom perspective view of theprinted circuit board; FIG. 22 is a perspective exploded view showing alight pipe in the paddle of the switch; FIG. 23 is a perspective view ofthe light pipe; and, FIG. 24 is a sectional view along the line 24-24 ofthe switch of FIG. 3.

Referring to FIGS. 14 and 17, there is shown exploded views of baseassembly 300 and frame assembly 400 which, when joined together andcoupled to the rocker paddle 111 forms the single pole switch 110. FIG.15 shows a perspective top view of the various parts in base assembly300 of switch 110. Base assembly 300 includes shell member 302 composedof electrically insulating material and having a longitudinal channel304 which extends along the length of shell member 302 and is centrallylocated between the side walls 306, 308 of member 302. Channel 304 issized to receive a slider 320 (more fully shown in FIG. 16) which canslide back and forth in channel 304. Located in shell member 302 andbeyond each end of channel 304 are clearance openings 310 for receivingfastening means 124 (see FIG. 18) such as rivets, screws or the likewhich secures the ground/mounting strap 123, the base assembly 300 andthe frame assembly 400 to each other. Side wall 308 of the shell member302 has an opening 309 (see FIG. 16) adapted to receive a stationaryterminal assembly 312, and side wall 306 has an opening 384 forreceiving brush terminal assembly 346, each more fully shown in FIG. 16.

Referring to FIG. 16, stationary terminal assembly 312 which is ofconducting material such as brass, etc. consists of a rectangular plate313 and a substantially non-yielding contact bearing arm 314 bent at aright angle to the plate and having a contact 316. A slot 318 located inrectangular plate 313 is a clearance opening for terminal screw 305which threads into pressure plate 323 located behind rectangular plate313. In operation, as terminal screw 305 is tightened, the bottomsurface of the head of terminal screw 305 and pressure plate 323 movetoward each other to clamp the rectangular plate 313. Stationaryterminal assembly 312 is provided for connection to an electricalconductor by either placing a turn of electrical conductor such as awire under the head of the terminal screw 305 or by inserting a straightend of the conductor between the pressure plate 323 and the rectangularplate 313, and then tightening terminal screw 305 to lock the conductorbetween plates 313 and 323, or the plate 313 and the head of the screw305. Looking at side wall 308 of shell member 302, each of the two sideedges 311 of opening 309 has a vertical slot or rail 315 for receivingand holding the side edges of rectangular plate 313 of the stationaryterminal assembly. Sliding the rectangular plate 313 down into the slotsor rails 315 in the edges of the opening 309 positions and holds thestationary terminal assembly 312 in position within opening 309 of sidewall 308 of shell member 302.

Brush terminal assembly 346 includes a rectangular plate 380 composed ofelectrical conducting material such as brass etc., which supports ayieldable contact bearing arm 344 having a contact 307. A slot 381located in rectangular plate 380 is a clearance opening for terminalscrew 386 which freely passes through the slot 381 and threads intopressure plate 388. Tightening terminal screw 386 clamps the rectangularplate 380 between the bottom surface of the head of the terminal screw386 and the pressure plate 388. Brush terminal assembly 346 is providedfor connection to an electrical conductor by either placing a turn ofthe conductor under the head of the screw or inserting a straight end ofthe conductor between the pressure plate 388 and the rectangular plate380. Tightening the screw 386 locks the conductor between the screw headand rectangular plate 380, or between plate 380 and pressure plate 388.Looking at side wall 306 of shell member 302, the two edges 303 ofopening 384 each has a narrow vertical slot or rail 317 for receivingand holding the side edges of rectangular plate 380. Sliding rectangularplate 380 of brush terminal assembly 346 down into slots or rails 317 inthe edges 303 of opening 384 positions and holds the brush terminalassembly in opening 384 of the side wall 306 of the shell member 302.

The stationary terminal assembly 312 and the brush terminal assembly 346are made of conductive material so that a circuit can be completedbetween the conductive wires connected to screw terminals 305 and 386.Preferably, the conductive components of the switch are all ofsubstantial grade, good quality electrical materials so that substantialcurrents, for example 10 to 20 amperes, can repeatedly be carried forextended periods of time without significant heat generation, electricallosses or excessive arcing. Such materials can include silver alloys forthe contacts, beryllium copper alloy for the brush arm and brass for theremaining conductive components.

Referring to FIGS. 15 and 16, slider 320, when positioned withinlongitudinal channel 304 can freely slide back and forth between theside walls 319, 321 from one end of the channel to the other end of thechannel. Slider 320 has, at one end, a rectangular funnel shaped slotopening 322 which extends completely through the slider and is providedto receive cam follower 370 of cam 366. It is understood that therectangular funnel shaped slot opening 322 is not restricted to an endof the slider, but can be located anywhere along the slider. Projectingdownward from the bottom surface of slider 320 and about mid-way betweenthe ends of the slider is a triangular shaped cam follower 324.Projecting upward from the top surface of the slider 320 and aboutmid-way between the slider ends is a hold down projection 326. Alsoprojecting upward from the top surface of the slider is a brush terminalcontrol projection 327. The space 329 between hold down projection 326and brush terminal control projection 327 is provided to receiveyieldable contact arm 344 of brush terminal assembly 346. When yieldablecontact arm 344 is positioned in space 329, arm 344 is stressed indirection A and, therefore, pushes against projection 327 and urges theslider to move in direction B. Movement of the slider 320 in direction“A” will cause projection 327 to urge yieldable contact arm 344 to bendin direction A and move away from stationary contact 316. Movement ofthe slider 320 in direction “B” causes brush terminal control projection327 to move in direction B which allows yieldable contact arm 344 tospring back and allow contact 327 to make electrical contact withstationary contact 316. A bumper support member 328 which projectsoutward from the side of the slider 320 provides support for a rubber Oring 330. With the slider located in longitudinal channel 304, O ring330 moves back and forth between stops 332, 334 of opening 336 in sidewall 321 (see FIG. 15) as the slider is driven from one end of channel304 to the other. The O ring 330 is used to cushion the stopping of theslider 320 by contacting stops 332, 334 located at the ends of opening336 in wall 321. Contact 317 of brush terminal assembly 346 (see FIG.16) is biased by yieldable contact arm 344 to move toward stationarycontact 316. To help offset some of the force exerted by arm 344 whichurges slider 320 in direction B, a helper spring 338 is provided. Helperspring 338 also helps to balance the feel of the rocker paddle 111 asthe switch is operated.

Yieldable contact arm 344 of brush terminal assembly 346 is springbiased to move contact 317 toward stationary contact 316. Therefore,more force is needed by the slider 320 to move contact 317 on yieldablecontact arm 344 out of engagement with stationary contact 316 than isneeded to close the contacts. Referring to FIG. 16, helper spring 338 isused to help overcome this force. Helper spring 338 is a strip of flatspring metal folded about its center with a generous radius to have twolegs 337, 339 which form an inverted V. The inverted V shaped helperspring 338 fits in chamber 340 at one end of channel 304 (see FIGS. 15and 16) with the apex of the V being at the top of the chamber. Asslider 320 is moved in direction B, the spring bias of yieldable contactarm 344 assists in closing contacts 316, 317. As the slider continues tomove and the contacts close, the end 342 of slider 320 contacts leg 339of helper spring 338 and urges it to move toward leg 337. At this time,helper spring 338 is compressed and biases slider 320 to move indirection A. When the contacts 316, 317 are being opened, helper spring338 urges slider 320 to move against the force of the yieldable contactarm 344. Thus, helper spring 338 helps to overcome the force exerted bythe yieldable contact arm 344 of the brush terminal assembly 346 as theyieldable contact arm 344 is being moved in direction A by the slider320 to open contacts 316, 317.

Wall 348 at an end of chamber 340 contains a slot opening 350 whichallows the end 342 of slider 320 to enter chamber 340 and engage andmove leg 339 toward leg 337 of helper spring 338. Wall 348 helps to keephelper spring 338 within the chamber 340.

As seen in FIG. 24, located directly beneath longitudinal channel 304and opening into channel 304 is spring chamber 354. Spring chamber 354is elongated, has a rectangular cross-section and contains a flat camshaped leaf spring 352. The spring chamber 354 can be centrally andsymmetrically disposed in the base assembly 302 and has support bars 356spaced from each end for supporting flat cam shaped leaf spring 352.Located beyond each support bar 356 is an end pocket 365. The overalllength of spring chamber 354 is determined by the length of the flat camshaped leaf spring 352.

Flat cam shaped leaf spring 352 can be formed from a flat strip ofspring steel to form a flat cam shaped leaf spring having a profilesubstantially similar to that shown in FIGS. 16 and 24. The flat camshaped leaf spring 352 has a profile that is symmetrical about a centerapex 358. Moving along the spring 352 from the apex 358 to an end, thespring has a short down sloping cam portion 359 on each side of the apex358 which, together with support sections 357 forms a valley 360, 362 ateach side of the apex. The support sections 357 rest on support bars 356and terminate in U shaped outer end portions 364 which resides in endpockets 365. The apex 358, the centrally located rise of the spring andthe short down sloping cam portions 359 on each side of the apex andjoined by support sections 357 provide a surface discontinuity ratherthan a smooth transition for the cam follower 324 as it travels over theapex 358.

Continuing with FIGS. 16 and 24, cam 366 is used to urge the slider 320to move back and forth in longitudinal channel 304 to open and close thecontacts 316,317 of the switch. Cam 366 has two cylindrical shapedprojections 368 aligned with each other and which extend out from thesides to form a support shaft rotatably received by support bearingopenings 378 located in side walls 319, 321 of the longitudinal channel304. In operation, cam 366 rocks back and forth in a clockwise andcounterclockwise direction about the axle defined by the projections368. Extending downward and below the cylindrical shaped projections 368is cam follower 370 which fits in the rectangular funnel shaped slotopening 322 in slider 320 with minimum clearance. Extending upward fromprojections 368 is cam control surface 430 (see FIG. 16) having a firstpocket 374 located at the left of the cam, and a second pocket 372located at the right of the cam, see FIG. 24. Looking at the profile ofthe cam 366 as shown in FIG. 24, pocket 372 is at the right side of theaxes of rotation of the cam, and pocket 374 is at the left side of theaxes of rotation of the cam. Thus, when the slider is at its right handposition, application of a downward force on pocket 372 will cause thecam follower 370 to rotate in a clockwise direction to cause slider 320to move to the left. In a similar way, application of a downward forceon pocket 374, when the slider is at its left hand position, will causethe cam follower 370 to rotate in a counterclockwise direction to causethe slider to move to the right. Thus, pressing down on pocket 372causes the cam to rotate clockwise which causes the cam follower 370 tomove the slider to the left. Thereafter, pressing down on pocket 374will now cause the cam to rotate counterclockwise to cause the camfollower to move the slider to the right. Alternately pressing onpockets 372 and 374 will cause the slider to move back and forth, firstin one direction and then in the other direction.

Referring to FIGS. 14, 17 and 18, projecting upward from the bottomfloor member 401 of frame assembly 400, and of the same material as thefloor member, are two hook shaped members 396 which are provided toengage and pivotly hold cooperating hook members 418 (see FIG. 17) whichproject down from subplate 412 attached to rocker paddle 111. Frameassembly 400 includes a clearance opening 402 located in floor member401 which is aligned with the top of cam 366 and through which anactuator 405 (See FIGS. 18 and 19) of cam driver 431 projects to engageand operate cam 366. The opening 402 is at the bottom of an upwardlyprojecting cylinder and is adapted to receive a cover plate 404 (seeFIG. 19) having an opening 402 through which actuator 405 (see FIGS. 18and 19) of cam driver 431 projects through to engage and operate cam366.

Looking at FIG. 19, cam 366 is operated by cam driver 431 which consistsof a cylindrical shaped member 409, a plunger 403, an actuator 405, anda conical shaped coil spring 407. The cam driver 431 engages and drivescam 366, first in a clockwise direction, then in a counter-clockwisedirection each time plunger 403 is moved down. The open endedcylindrical shaped member 409 is an integral part of the frame 400, butis shown as a separate part for clarity. In the actual device, member409 projects upward from the top surface of floor member 401 of frameassembly 400. Member 409 contains a first opening 413 at its lower endand a second opening 415 at its upper end. The first opening 413 at thelower end of the cylindrical shaped member 409 is sufficiently large toavoid obstructing or interfering with clearance opening 399 located incover plate 404 when cover plate 404 is coupled to the bottom surface offloor member 401. The cylindrical shaped member 409 supports an internalridge 417 located between openings 413, 415.

To assemble the cam driver (FIG. 19) plunger 403 is inserted throughopening 399 in the floor member 401 and into member 409. Plunger 403slidably fits within member 409. The outside diameter of plunger 403 isslightly smaller than the diameter of opening 415 in the upper end ofcylindrical shaped member 409 to allow plunger 403 to move up and downin opening 415 without binding. Plunger 403 has a skirt 433 which formsan external, outwardly projecting ridge 429. Shoulder 417 in cylindricalshaped member 409 and ridge 429 on plunger 403 engage each other to keepplunger 403 captive within member 409.

Actuator 405 is then inserted through opening 399 and into plunger 403.Actuator 405, which can be composed of a metal such as brass or steel,or of a plastic having suitable characteristics, is a shaft 421 having agenerous radius at one end 422 and first 423 and second 425 collars atthe other end. Collar 423 is smaller in diameter than collar 425 andcollar 423 has a diameter slightly larger than the inside diameter ofthe apex of conical spring 407 and fits into and frictionally engagesthe apex end of spring 407. The end of collar 425 is located withinopening 428 of plunger 403 and contacts internal projection 427.

Thereafter, spring 407 is inserted through opening 399 in the floormember 401 and onto shaft 421 of the actuator 405. Spring 407 has aconical shape, the apex of which is wrapped around and frictionallyengages collar 423 and the base of spring 407 has a diameter that islarge enough to extend beyond clearance opening 399 in cover plate 404when said plate 404 is secured to the bottom surface of the floor member401 to avoid interfering with shaft 421 as it moves up and down andpivots back and forth in rectangular clearance opening 399. Thereafter,cover plate 404 is positioned to cover opening 402 in the floor member401 and is securely coupled to the bottom surface of the floor member401 with adhesive or the like. Clearance opening 402 in the cover plate404 can have a long dimension along the length of the switch and a smalldimension along the width of the switch. The small dimension of opening399 is slightly larger than the diameter of shaft 421 to permit theshaft 421 to move in opening 399 without binding and the long dimensionof opening 399 allows shaft 421 to engage and freely rock back and forthwhile operating cam 366 without binding.

Referring to FIG. 18, cylindrical shaped member 409 which is an integralpart of the floor member 401 and projects upward from said floor memberis shown as being separated from said floor member for clarity only. Ifdesired, a small projection 406 which extends upward from the floormember 401 of frame assembly 400 and of the same material as the floormember 401 can be provided to engage the lower end of a helical helperspring 408 (see FIG. 24) which can be used, if desired, to help urge therocker paddle 111 to its out position. In normal use, spring 407, actingon plunger 403 through actuator 405 provides sufficient force to urgepaddle 111 away from frame assembly 400. However, in those instanceswhere additional force may be desired, helper spring 408 can beprovided. The outside diameter of the projection 406 (see FIGS. 14 and24) is slightly larger than the inside diameter of helical helper spring408 and is inserted into the lower end of the helical helper spring. Theupper end of helical helper spring 408 can be located within and heldcaptive in a pocket 410 (see FIGS. 17 and 24) located on subplate 412.Subplate 412 is secured to the underside of the rocker paddle 111 byadhesive and/or by plastic locking projections which extend from theunderside of the rocker paddle 111, pass through openings 429 in thesubplate and are then staked over, or the like.

Referring to FIG. 17, there is shown an exploded perspective view of thebottom of base assembly 300, frame assembly 400 and rocker paddle 111 ofa single pole switch. Referring to the frame assembly 400 which can be aunitary member formed of a suitable plastic, two projections 414 whichare a part of the cover plate 404 extend out from the bottom surface ofthe floor 401 are positioned to contact the top surface of the axlesupport shaft formed by the aligned cylindrical projections 368 of thecam 366. Projections 414 help prevent the cylindrical projections 368from moving out of their bearing surfaces in the side walls of thelongitudinal slider receiving channel. Also projecting downward from thebottom surface of the frame assembly 400 is slider hold down projection416 which slidably contacts hold down projection 326 on slider 320.Projection 416, by contacting projection 326 on slider 330, preventsslider 320 from being pushed up and out of channel 304 by the upwardforce of flat cam shaped leaf spring 352 pushing up on cam follower 324.

Subplate 412, which is attached to the underside of rocker paddle 111,is a unitary member of a plastic material having two hook shaped members418 formed thereon which project down from the bottom surface. The hookshaped members 418 are positioned to engage hooks 396 (see FIG. 14) onframe assembly 400. Hooks 418, when engaged by hooks 396, allow therocker paddle 111 to pivot about studs 420 rotatably coupled to openings424 toward and away from the frame assembly 400 and, at the same time,prevent the subplate 412 and attached rocker paddle 111 from beingseparated from the frame assembly 400. If desired, a downward extendingring can be provided on the subplate 412 which is aligned withprojection 406 on the frame assembly 400 to hold the ends of helicalhelper spring 408 in position when a helper spring is used. The insidediameter of ring 410 should be slightly larger than the outside diameterof the helical helper spring to permit the end of the helper spring tobe placed within ring 410.

Two arms 422 which project beyond the rear end of the subplate 412 eachsupports a circular stud 420, one on the outside surface of each arm,which are axially aligned with each other to form a common axle. Thecircular studs 420 snap into openings 424 in the frame assembly 400 toform a hinge about which the subplate 412 and the rocker paddle 111pivot relative to the frame and base assemblies. The subplate 412 issecured to the bottom surface of the rocker paddle 111 with an adhesiveand/or plastic locking projections or the like to form a unitaryassembly.

The switch here disclosed has an on-off indicator 112 such as a light toindicate to a user when the switch is in its conducting state and in itsnon-conducting state. The light can be of a color or white. In practice,a blue light was found to be preferred. Referring to FIGS. 21A and 21B,there is shown a top plan view and a bottom perspective view of aPrinted Circuit Board (PCB) 430 which fits within frame assembly 400.Located on the top surface (FIG. 21A) of the PCB 430 is resistor 432,diode 434 and LED 441 connected to spring terminals 436, 438. Referringto FIG. 14, frame assembly 400 fits on top of base assembly 300 and hasopenings for spring terminals 436, 438 to project through the frameassembly and make contact with plate 313 of the stationary terminalassembly 312 and plate 380 of the brush terminal assembly 346 to supplypower to the PCB. The LED 441 on the PCB indicates the conductive stateof the switch by being “on” or “off”. In operation, LED 441 is “on” whenthe contacts of the switch are open, and the LED is “off” when thecontacts of the switch are closed. FIG. 211B shows the conductive pathsbetween the spring terminals and the electrical components.

Referring now to FIG. 23, there is shown a light pipe 440 which isconnected to the underside of the rocker paddle 111 (see FIG. 22) tooptically connect the LED on the PCB to an opening in the lower edge ofthe rocker paddle 111. One end 442 of the light pipe, which ispositioned to receive light from the LED, has a spherical face 443 forreceiving light from the LED, and the other end 446 of the light pipehas a diffuser texture exit surface 448 which is the indicator 112 inthe edge of the rocker paddle 111 for indicating to a user theconductive state of the switch. The light pipe can have any desiredserpentine shape to provide flexibility when positioning the PCB havingthe LED within the switch. In another embodiment, the indicator 112 canbe located to be at any place on the rocker paddle 111.

Referring to FIG. 24, as the switch is assembled, the helper spring 338is inserted into chamber 340, flat cam shaped leaf spring 352 is placedinto spring chamber 354 and slider 320 is placed into longitudinalchannel 304 and above leaf spring 352. The end 342 of the slider 320faces the helper spring 338 and the triangular shaped cam follower 324,which projects from the bottom of the slider, slidably engages the topsurface of flat cam shaped leaf spring 352. Cylindrical projections 368of cam 366 are placed within bearing surface openings 378 in side walls319, 321 of longitudinal channel 304 with cam follower 370 beingpositioned within rectangular funnel shaped slot opening 322 of slider320. Stationary terminal assembly 312 is positioned in the opening 309,and brush terminal assembly 346 is positioned within opening 384. As thebrush terminal assembly 346 is being placed in position, the yieldablecontact arm 344 is moved backward against the force of the spring armand is positioned within slot 329 located between the hold downprojection 326 and the brush terminal control projection 327 of slider320. At this time all the various components are within the switch base300.

Referring now to the frame assembly 400 (see FIG. 18) and the cam driver431 (see FIG. 19) which is coupled to and is an integral part of theframe assembly. Cam driver 431 has a plunger 403 which is positionedwithin cylindrical shaped member 409 by inserting the plunger 403through the bottom opening 413 of the cylindrical shaped member 409which projects upward from the top surface of the floor member 401 untilthe outwardly extending ridge 429 formed by the projecting skirt 433engages inwardly projecting shoulder 417 in cylindrical shaped member409. Thereafter, actuator 405 is inserted through the bottom opening ofthe cylindrical shaped member 409 and into the plunger 403 until the topconvex surface of collar 425 contacts internal projection 427 whichextends downward from the inside surface of the top of the plunger 403.The convex top surface of collar 425 is provided to allow the actuator405 to more easily rock back and forth as it moves down and contacts cam366. Conical shaped coil spring 407 is now placed around the actuator405 with the apex of the coil spring being positioned around the collar423. At this time the cover plate 404 is attached to the bottom surfaceof the floor member 401 and positioned to allow the shaft 421 to extendthrough the opening 399. The PCB board is now positioned on to the floormember 401 with the spring contacts 436, 438 extending thru the openingsin the floor member 401 to make electrical contact with stationaryterminal assembly 312 and brush terminal assembly 346.

The frame assemblage 400, which includes the PCB having the LED,resistor, diode and spring terminals 436, 438, is now placed over theswitch base assembly 300 and the ground/mounting strap 123 is attachedto base assembly 300 with screws, drive pins, rivets or the like toconnect the ground/mounting strap 123, switch base assemblage and frameassemblage together. In the embodiment shown, when the rocker paddle 111is attached to the frame 400, the conical shaped coil spring 407, actingthrough the plunger 403, exerts an upward force on the rocker paddle 111and, in addition, spring 407 urges the plunger to its extended outposition. The subplate 412 has a cutout 441 through which the plunger403 passes to contact the underside of the rocker paddle 111. Thus, thetop surface of the plunger 403 contacts the bottom surface of the rockerpaddle 111 and it is the upward force of the spring 407 which biases thepaddle to its outward position and which a user must overcome whenpressing on the paddle. In some instances, it may be desirable to have aswitch which requires a greater force to operate. If a greater force isdesired, it can be obtained with helical spring 408 where the lower endis placed over projection 406 on the frame and the top is placed withinthe pocket 410 of the subplate. The light pipe 440 is attached to theunderside of the subplate and the end 443 is located to receive lightfrom the LED and the end 446 is positioned in the opening in the bottomedge of the paddle and is the indicator which shows the conductive stateof the switch. The projections 420 on the arms 422 of the subplate 412are snapped into the openings 424 in the frame assembly 400 to form thehinge about which the rocker paddle 111 and the frame assembly 400 pivotrelative to each other. Thereafter the rocker paddle 111 which includesthe subplate 412, is pressed down toward the frame assembly until hooks418 engage hooks 396. At this time the bottom or underside of the paddlecontacts the top surface of the plunger 403 and the application offinger pressure on the rocker paddle will move it toward the frameassembly against the force of spring 407 to drive the shaft 421 of theactuator 405 down through opening 402 to engage the cam eccentricsurfaces 372, 374 and operate cam 366.

FIG. 24 is a sectional view of a single pole switch where the contactsof the switch are closed and the switch is in its conducting state. Thenext time the rocker paddle is pressed, actuator 405, acting against theforce of spring 407, is urged to move down to contact the ramp of cam366 and slide toward the right and enter pocket 372. Continued pressingon the paddle causes the actuator 405 to continue to move down androtate cam 366 clockwise about cylindrical projections 368. This causescam follower 370 to rotate in a clockwise direction and move slider 320to the left. As slider 320 moves to the left, the triangular shaped camfollower 324 moves out of depression 360 of the flat cam shaped leafspring and across the right support section 359 toward the centrallylocated apex 358. As the slider continues to move to the left,triangular shaped cam 324 deflects leaf spring 352 downward becauseprojection 326 on slider 320, in cooperation with slider hold downprojection 416, prevents the slider 320 from moving upward. As thetriangular shaped cam 324 moves over the top of apex 358 of the camshaped leaf spring and toward the left support section 359 of the apex,the leaf spring starts to spring back to its original unstressed upposition. This upward movement of the leaf spring, acting on the shapedcam follower 324, helps drive the cam follower 324 and the slider 320 tothe left until the cam follower 324 comes to rest in depression 362. Atthis time the contacts of the switch are separated from each other andthe switch is in its off state. Thus, the cam shaped leaf spring 352, incombination with the cam follower 324 helps to move the slider to eitherthe left or right depressions 362, 360 to help open and close thecontacts. The next time that the rocker paddle is depressed, actuator405 will enter pocket 374 of the cam to cause it to rotate in acounterclockwise direction which will cause cam follower 324 on theslider to depress the leaf spring as it moves to the right. As the camfollower 324 continues to move to the right and as it passes apex 358,the depressed leaf spring starts to spring up to return to its originalposition. This upward movement of the leaf spring, in combination withthe counterclockwise rotation of the cam 366 causes the cam follower 324to move toward the right until it reaches depression 360 at which timethe switch contacts are closed and the switch is in its on state.Continued pressing and releasing the rocker paddle of the switchalternately opens and closes the contacts of the switch. The state ofconduction of the switch is displayed to a user by the absence orpresence of light at the indicator 112 in the edge of rocker paddle 111.The light can be from an LED, a neon lamp or a pilot light on the PCBwhich is connected to the stationary and brush terminal assemblies. Whenthe contacts of the switch are closed, there is no potential differenceacross the lamp and the lamp will remain dark. When the contacts of theswitch are open, there will be a potential difference across the lampand the lamp will be lit.

Referring to FIGS. 25A, 2513 and 25C, there is shown sectional views ofthe rocker paddle of the switch of FIG. 14. FIG. 25A is a section alongthe line 25A-25A of FIG. 14; FIG. 25B is a section along the line25B-25B of FIG. 14; and, FIG. 25C is a section along the line 25C-25C ofFIG. 14. The width of the paddle is substantially 1.80 inches and thelength of the paddle is substantially 2.77 inches. The face of thepaddle has a vertical axis along its length and a horizontal axis alongits width where the face of the paddle along its vertical axis has asurface of positive first differential comprised of a combination ofsplines drawn between points of varying distances from a datum plane andzero second differential where the rate of height increase of theindividual splines is constant. The horizontal axis has a surface of apositive first differential and negative second differential comprisedof a combination of splines drawn between points of varying distancefrom a datum plane. Referring to FIG. 25A, the surface along line25A-25A lies between two profile boundaries substantially 0.139 inchesapart, perpendicular to a datum plane equally disposed about the trueprofile and positioned with respect to a datum plane. The basicdimensions and the profile tolerance establish a tolerance zone tocontrol the shape and size of the surface. The surface is substantially2.77 inches in length. Within that length, a surface is defined by thedimensions of about twenty equidistant points which are about 0.139inches apart. Each dimension indicates that point's distance to a datumplane, the back, flat surface of the rocker paddle 111. Moving from leftto right in FIG. 25A, the dimensions increase from about 0.277 to about0.328 inches at the center, and then decreases to about 0.278 inches atthe right end. This progression defines a surface of increasing and thendecreasing height where the points are connected by individual splines.The points are not connected by a single arc and the rate at which thesurface height increases in not constant. The rate of height increase ofthe individual splines decreases from left to right to the center, andthen increases from the center to the right end. Thus, the seconddifferential of the surface is negative from each end toward the center.That is that the difference between some of the points distancedimension from an end toward the center decreases. Thus, from an end tothe center, the surface has a contour of positive first differential andnegative second differential, comprised of a combination of splicesdrawn between points of varying distance from a datum plane. Thisdescription substantially describes the paddle's face along the lines25A-25A, 25B-25B and 25C-25C of FIG. 14.

The section along line 25B-25B of FIG. 14 which runs along thehorizontal center line of the paddle is shown in FIG. 25B and defines asurface having positive first differential and substantially negativesecond differential from an end to the center line. The seconddifferential is substantially negative because not all successive pointshave a constant increase.

The section along line 25C-25C of FIG. 14 which runs along the diagonalof the paddle is shown in FIG. 25C and defines a surface having apositive first differential and substantially negative seconddifferential from an end to the center line. The second differential issubstantially negative because not all successive points have a constantincrease.

FIGS. 25A-25C disclose, in detail, the dimensions of the paddle and,therefore, in the interest of brevity, the dimensions shown in the FIGS.25A, 25B and 25C are not here repeated.

Referring to FIG. 26, there is shown an exploded view of the switch withanother cam driver embodiment; and FIG. 27 is a sectional view alongline 24-24 of FIG. 3 where the cam driver is that shown in FIG. 26. Inthis embodiment, the cam driver 431 shown in FIG. 19 is replaced withcam driver 600. Cam driver 600 is composed of a flat ribbon ofsemi-flexible material such as spring steel bent back upon itself at itscenter to form a blunt end 602 and having a generous radius which formsthe blunt end 602 having a diameter which fits within the pockets 372,374 of cam 366. The ends 606 of the cam driver are bent outward at 90degrees to form two legs 604 which lie in the same plane and each ofwhich has an opening 608 for receiving a holding member for attachingcam driver 600 to the subplate 412. In this embodiment, subplate 412does not have cutout 433 (see FIG. 18), but is continuous to allow thecam driver 600 to be attached to the subplate. Cam driver 600 can beattached to the subplate with rivets, plastic projections which protrudefrom the subplate and pass through the openings 608 in the legs 604which are deformed with heat to secure the cam driver to the subplate,or by any other method. In this embodiment, spring 408 is used to urgethe paddle to its “up” at rest position. If desired, a channel 610 canbe formed on the subplate 412 for positioning at least one of the legs604. Except for the substitution of the cam driver 600 for the camdriver 431 disclosed in FIG. 19, and the absence of the cutout 433 insubplate 412, the construction and operation of the switch of theembodiment disclosed in FIGS. 26 and 27 is similar to that of the switchdisclosed in FIGS. 14-24.

Referring to FIG. 28, there is shown an exploded view of the switch withstill another cam driver embodiment, and FIG. 29, is a sectional viewalong line 24-24 of FIG. 3 where the cam driver is that of FIG. 28. Inthis embodiment, the cam driver 431 shown in FIG. 19 is replaced with asemi-flexible cam driver having a sharp end 700. Semi-flexible camdriver with sharp end 700 is composed of a closely wound helical spring701 of, for example, piano wire coupled at one end to a tip 702 whichhas a front end having a conical shape and a back end having acylindrical shape. The tip 702 can be of plastic, metal or the like. Theoutside diameter of the cylinder is slightly larger than the insidediameter of the spring 701 to enable it to be securely held by thespring 701 when inserted into the end of the spring, and is smaller thanthe diameter of the base of the conical shaped end to provide a shoulderwhich prevents the tip 702 from being pushed into spring 701. In thisembodiment, subplate 412 does not have a cutout 441, but is continuousto provide support for the cam driver 700. Subplate 412 has a smallcylindrical shaped projection which extends out from the bottom of thesubplate and has a diameter that fits snugly into and securely holds thetop end of the closely wound spring 701. The closely wound spring 701 isattached to the subplate by being pushed onto the projection on thesubplate. The tip of the conical shaped end 702 has a small diameterwhich allows it to fit into pockets 372 and 374 of cam 366. In thisembodiment, the spring 408 is used to urge the paddle to its “up” atrest position. Except for the substitution of the cam driver 700 withconical end for the cam driver 431 disclosed in FIG. 19, and the absenceof the cutout 433 on subplate 412, the construction and operation of theswitch of the embodiment disclosed in FIGS. 28 and 29 is similar to thatof the switch disclosed in FIGS. 14-24.

FIG. 30 is a front perspective view of a wall plate for a single wiringdevice such as a switch or a receptacle. The width of the face of thewiring device is approximately 55% of the width of the wall plate alongthe horizontal axis and approximately 56% of the length of the wallplate along the vertical axis. When the wiring device is a receptacle,the contour along the width of the receptacle face is substantially flatin one plane and is complex along the length of the face of thereceptacle with a substantially constant radius that is greater than 10inches and less than 40 inches, a preferred radius being substantially30.724 inches. The shape of the receptacle face is different from thatof the switch to allow for the proper seating of an inserted plug. Whenthe wiring device is a switch, its face has a vertical axis along itslength and a horizontal axis along its width where the face of therocker paddle along its vertical axis has a shape of positive firstdifferential comprised of a combination of splines drawn between pointsof varying distances from a datum plane and zero second differentialwhen the rate of height increase of the individual splines is constant.The horizontal axis has a surface of a positive first differential andnegative second differential comprised of a combination of splines drawnbetween points of varying distance from a datum plane. The wall platehas a surface configuration which allows it to be placed around a switchor a receptacle, or both a switch and a receptacle placed side by side,and which blends with the wiring device, or wiring devices, even thouthe surface configuration of the switch is different than that of thereceptacle. Referring to FIG. 30, the wall plate is substantially 4.92inches in length by 3.28 inches in width and has a single opening 100.When the wall plate of FIG. 30 is for more than a single wiring device,the opening 100 has no dividing members for receiving multiple wiringdevices, either a switch which has no frame or a receptacle, or anycombination of switches and receptacles. When the wall plate is for onewiring device, the dimensions of the wiring device is slightly less than2.81 inches in length by 1.83 inches in width to fit within the opening100. The width of the wall plate varies depending upon the number ofwiring devices ganged together in side-by-side relationship. The frontsurface of the wall plate here disclosed has a complex/compound shapesuch that the surface at the opening for the wiring device is furtherfrom the wall than it is at the outer edge of the wall plate.

Referring to FIG. 311B which is a sectional view along the line 31B-31Bof the wall plate of FIG. 30 along the horizontal centerline, from pointK, the outer left edge, to point L, the inner edge of the opening forthe wiring device. As shown in FIG. 31B, the surface lies between twoprofile boundaries substantially 0.002 inches apart, perpendicular to adatum plane, equally disposed about the true profile and positioned withrespect to the datum plane. The basic dimensions of the profileestablishes a tolerance zone which controls the shape and size of thesurface. The surface is substantially 0.73 inches in width. Within thiswidth, a shape is defined by the dimensions of ten equidistant points,more or less, which are approximately 0.073 inches apart. Each dimensionindicates that point's distance to the datum plane, the back (flat)surface of the wall plate, which begins at point K. Moving from left toright, the dimensions increase from about 0.243 inches to about 0.302inches. This progression defines a surface of increasing height,positive first differential, when the points are connected by individualsplines. The points are not connected by a single arc and the rate atwhich the surface height increases is not constant. The rate of heightincrease of the individual splines decreases from left to right, and thesecond differential of the shape is negative. That is, the differencebetween the first and second point's distance dimension is larger thanthe difference between the second and the third, etc. Thus, the surfacehas a contour of positive first differential and negative seconddifferential, comprised of a combination of splines drawn between pointsof varying distance from the datum plane. FIG. 31A is a sectional viewalong the line 31A-31A of FIG. 30; and FIG. 31C is a sectional viewalong the line 31C-31C of FIG. 30. FIGS. 31A; 31B and 31C show the wallplate for sections along lines 31A-31A, 31B-31B and 31C-31C of FIG. 30.

The section along line 31C-31C of FIG. 30 (see FIG. 31C), which runsalong the vertical centerline of the wall plate defines a surfacecontour having a positive first differential and zero seconddifferential, comprised of a combination of splines drawn between pointsof varying distance from a datum plane. The difference between any twosequential point dimensions is substantially 0.0037 inches and thissurface has a zero second differential because the rate of heightincrease of the individual splines is constant.

The wall plate 138 for a single wiring device shown in FIG. 30 includes,along the inside top edge, and the inside bottom edge, tooth shapedracks 80 for engagement with latching pawls 140 on the end 147 of themulti-function clips 130, 151. FIG. 32 is a sectional view of the bottomedge of the wall plate 138 along the line 32A-32A of FIG. 30; and FIG.33 which is a sectional view of the top edge of the wall plate 138 alongthe line 33A-33A of FIG. 30. The top outside edge of the wall plate (seeFIG. 33), has a recessed area 750 such as a channel having centrallylocated raised identifying nomenclature structure 752 such as letters ofthe alphabet, numbers and/or a symbol which can, for example, identifythe manufacturer of the device. FIGS. 34, 34A show views of a portion ofthe top edge of the wall plate of FIG. 30 showing the channel andidentifying nomenclature structure.

As shown in FIGS. 34 and 34A a channel 750 is in the top outside edge ofthe wall plate 138. The channel can be approximately three-quarters ofan inch in length and have a width which is less than the width of theedge of the wall plate. As shown in FIGS. 33, 34 and 34A, channel 750 isa rectangular depression defined by four walls 754, 756, 758 and 760.Located within the channel is raised identifying structure 752 such asthe name of the manufacturer, i.e., “LEVITON”. The height of the raisedidentifying structure can be 0.010 of an inch where the top surface ofthe raised identifying structure is substantially flush with the surfaceof the top edge of the wall plate.

When the wiring device is a switch as is here shown, the surface of therocker paddle of the switch is a continuation of contours of the wallplate, so that the surface of the wall plate complements the surface ofthe switch. When the wiring device is a receptacle, the contour alongthe width of the receptacle face is substantially flat in one plane andis complex along the length of the face of the receptacle with asubstantially constant radius. The shape of the receptacle face isdifferent from that of the switch to allow for the proper seating of aninserted plug. But, again, when the wiring device is a receptacle as ishere shown, the surface of the wall plate complements the surface of thereceptacle. The wall plate has no exposed mounting screws or othervisible metal hardware. When the wall plate is placed around a wiringdevice, the only visible parts are the wall plate 138 and the wiringdevice, the switch or receptacle. No fastening means such as screws,etc. for holding the wall plate in place are visible.

To attach the wall plate 138 to a wiring device, the edges 147 of pawls140 of the bottom and top multi-function clips 130, 151 engage toothshaped racks 80 located on the inside surfaces of the top and bottom endwalls 170 of wall plate 138. There are two tooth shaped racks 80 on theinside edge of each end wall 170 of the wall plate 138. Each toothshaped rack 80 contains a number of teeth each having an inclined frontface 84 and an inclined back face 86. Referring to FIG. 35, there isshown a fragmentary, enlarged perspective of the end 147 of the latchingpawl 144 of the multi-function clip engaging the tooth shaped rack 80 ofthe wall plate 138. When attaching a wall plate to a wiring device, thewall plate is placed over the wiring device and pushed in toward thewall. As the wall plate moves toward the wall, the end 147 of latchingpawl 140 of the multi-function clip engages the inclined front face 84of a tooth, and the pawl 140 deflects as it moves past the tip of thefirst tooth. Once the end of the latching pawl 140 is past the tip ofthe first tooth, it returns to its initial position and takes a positionbetween the inclined back face 86 of the tooth and the inclined frontface of the next tooth. This operation is repeated as many times as isneeded to position the top and bottom of wall plate 138 as close to thewall as possible. As tooth shaped racks 80 and pawls 140 at the top andbottom are independently operated, it is possible to position the wallplate 138 to closely follow the contour of the wall, even when the wallis not flat. This ability to follow the wall contour is appreciated whenthe wall plate 138 is large, such as a wall plate positioned aroundmultiple wiring devices.

Referring to FIG. 36, there is shown a fragmentary, enlarged sectionalside view of the wall plate 138 and tab 120 of the alignment plate 14 toindicate how the two components can be separated following latching.Once the ends of latching pawl 140 are positioned in a valley betweentwo teeth, it becomes difficult to dislodge the wall plate 138 from thewiring device(s) and the wall. To help in the removal of the wall plate,a slot 74 is formed in the bottom end 170 of wall plate 138 to provideaccess to tab 120. A small, flat tool blade such as a screw driver blade76, or the like, can be moved through slot 74 in end 170 to contact boththe outer surface of tab 120 and the back wall of slot 74. By moving theblade 76 using the back wall of slot 74 as a fulcrum, the force appliedto tab 120 will separate wall plate 138 from the wiring device and thewall. As tool 76 can apply a great deal of force to tab 120, it ispossible to separate the pawl 140 from engagement with the tooth shapedracks 80 and thus the wall plate from the wiring device and the wall.

Referring to FIG. 37, there is shown an exploded view of a box, analignment plate and a wall plate for two wiring devices. There is nopartition or dividing member located in either the wall plate opening100 or the alignment plate opening 116 to separate the two wiringdevices from each other. The two wiring devices can be placed in adouble ganged box 160 made up, for example, of two single boxes joinedby fasteners 162 extending through the threaded apertures 164 of twojoining ears 166. Alignment plate 114 has a single opening 116, fouropenings 117 and four alignment pins 118 for receiving the two wiringdevices such as two switches, a receptacle and a switch, or tworeceptacles.

Wall plate 138 can have four tooth shaped racks 80 on the inside surfaceof the top and bottom end walls for receiving four latching pawls wherethe two center tooth shaped racks receive one pawl from each wiringdevice. Also, the alignment plate has two tabs 120, which are accessiblevia slots 74 in the bottom end wall of wall plate 138. The independentoperation of the pawls 140 with their respective racks 80 allows thewall plate 138 to compensate somewhat for lack of flatness of a wall inwhich the wiring devices are installed.

Referring to FIG. 38, there is shown an exploded view of alignment plate114 having a single opening 116 and a wall plate 138 for three wiringdevices ganged together and mounted in three boxes (not illustrated).Wall plate 138 has a single opening 100 with no dividing or separatingmembers for receiving three wiring devices positioned side by side andhas three sets of tooth shaped racks 80 (one set for each wiring device)on the inside surface of the top and bottom end walls. The two end rackseach receive a single latching pawl and the center racks receive twolatching pawls. Alignment plate 114 has a single opening 116 with nodividing or separating members, three sets of openings 117 and threesets of alignment pins 118 for receiving three wiring devices.

Referring to FIG. 39, there is shown an exploded view of attachmentplate 114 having a single opening 116 with no dividing or separatingmembers for receiving four wiring devices and wall plate 138 for fourwiring devices which are to be ganged together. Wall plate 138 has asingle opening 100 with no dividing or separating members for receivingfour wiring devices positioned side by side and the attachment plate 114has a single opening 116 with no dividing or separating members forreceiving four wiring devices positioned side by side, and four sets ofopenings 117 and four sets of alignment pins 118. The wall plate hasfour sets of tooth shaped racks 80 (one set for each wiring device) onthe inside surface of the top and bottom end walls.

Referring to FIG. 40, there is an exploded view of alignment plate 114having a single opening 116 with no dividing or separating members forreceiving five wiring devices and wall plate 138 for five wiring deviceswhich are to be ganged together. Wall plate 138 has a single opening 100with no dividing or separating members for receiving five wiring devicespositioned side by side and the alignment plate 114 has a single opening116 with no dividing or separating members for receiving five wiringdevices positioned side by side, and five sets of openings 117 and fivesets of alignment pins 118. The wall plate 138 has five sets of toothshaped racks 80 (one set for each wiring device) on the inside surfaceof the top and bottom end walls.

Referring to FIG. 41, there is shown an exploded view of alignment plate114 having a single opening 116 with no dividing or separating membersfor receiving six wiring devices and wall plate 138 for six wiringdevices which are to be ganged together. Wall plate 138 has a singleopening 100 with no dividing or separating members for receiving sixwiring devices positioned side by side and the alignment plate 114 has asingle opening 116 with no dividing or separating members for receivingsix wiring devices positioned side by side, and six sets of openings 117and six sets of alignment pins 118. The wall plate has six sets of toothshaped racks 80 (one set for each wiring device) on the inside surfaceof the top and bottom end walls.

Each wall plate shown in the Figs. can be made of conductive material orof non-conductive material. Where the wall plate is made ofnon-conductive material such as plastic, a conductive coating can besprayed, plated, etc. to the front, back or both the front and backsurfaces of the wall plate to provide a conductive path from the wallplate to ground on the ground/mounting strap and/or the box through aconductive path. The conductive path can be from the wall plate, throughthe latching pawls 140 of the multi-function clips 130, 151, thealignment pins 118 on the alignment plate contacting the multi-functionclips, and the threaded fasteners contacting the multi-function clipsand the box; or it can be through the latching pawls 140 of themulti-function clips and the threaded fasteners contacting themulti-function clips to the ground terminal on the ground/mounting strapand/or the ground connected to the box.

The present invention contemplates a system wherein multiple electricalwiring devices in numbers not expressly set forth hereinabove may beutilized, without departing from the spirit or lawful scope of theinvention.

While there have been shown and described and pointed out thefundamental novel features of the invention as applied to the preferredembodiments, it will be understood that various omissions andsubstitutions and changes of the form and details of the devicesillustrated and in their operation may be made by those skilled in theart without departing from the spirit of the invention.

1. An electrical receptacle for mounting within a wall box and adaptedto be surrounded by a wall plate, the electrical receptacle having arectangular face wherein the surface along the width of the receptacleface is substantially flat and the surface along the length of the faceof the electrical receptacle is a single curved plane having asubstantially constant radius that bulges outward.